Replacing a front door while keeping the existing frame is a simple way to improve your home’s look and security. A new door boosts insulation and enhances curb appeal if your old one is damaged, drafty, or outdated. To hang an exterior door in an existing frame, start by measuring the old door. Then, prepare the new door to match the measurements. Finally, install the new door into the existing frame.
If the frame is in good condition, installing a new exterior door is a manageable DIY project. This article provides a step-by-step guide to help you complete the installation.
| Project difficulty: Intermediate Estimated time to complete: 3 to 4 hours Project cost: $432 |
I asked Steven Long, the founder of Highmark Handyman, when it is best to replace just the exterior door rather than installing a prehung unit. According to him, it depends on the condition of the existing door frame.
He said, “In my experience, replacing just the exterior door instead of installing a prehung unit is ideal when the existing door frame is in good condition. If the frame is structurally sound, square, and free of rot or damage, swapping the slab can save time and labor costs.
“It’s also a good option when maintaining historical or custom trim work that would be difficult to replicate. Additionally, if the home has a non-standard rough opening that would require extensive modifications for a prehung fit, replacing only the door can be a simpler solution.”
Supplies Needed
Materials Needed
- Entry door slab
- Hinges
- Lockset
- Deadbolt
- Strike plates
- Wood screws
- Masking tape
Tools Needed
- Hammer
- Screwdriver
- Circular saw
- Hand plane
- Sandpaper
- Tape measure
- Straightedge
- Pencil
- Speed square
- Chisel
- Drill
- Hole saw (2 1/8-inch)
- Spade bit (1 inch)
How to Prepare for Exterior Door Installation
Before installing a new exterior door, you need to prepare properly. This includes removing the old door, measuring it, and adjusting the new door to fit. Doing this ensures the new door fits securely in the frame.
Step 1: Remove the Old Door
To remove the old door, open it and secure it in place. Take out the hinge pins with a hammer and screwdriver, then lift the door off the hinges. If something is jamming the door, loosen it by gently wiggling it free. Finally, set the old door aside and check the frame for any damage before installing the new one.
After removing the door, take off the hinges from both the door and the frame. Also, remove the door handle and deadbolt to make measuring the old door easier in the next step. Learn how to take the door off its hinges so you’ll be prepared if you tackle this project.
Related: How to Remove a Door Hinge Pin
Step 2: Measure the Old Door
After you remove the door, measure it to ensure your replacement fits properly. Start by measuring the width by running your tape measure horizontally across the door. Then, measure the height from top to bottom. Lastly, check the door’s thickness, as this must match the new door for a proper fit.
Once you have these measurements, inspect your replacement slab door. Confirm that it matches the size of your old door and meets your needs. Next, measure the backset by checking the distance from the edge of the door to the center of the handle and lock. Transfer all measurements to the new door, making adjustments if needed to ensure a precise fit.
Step 3: Cut and Fit the Replacement Door
If you find the new door too large, trim it for a proper fit. Use a circular saw or a hand plane to shave off small amounts from the edges. Mark your cut lines carefully with a pencil and straightedge before cutting.
If you need to remove a significant amount, use a saw for larger cuts and a hand plane for fine adjustments. Always sand the edges smooth after cutting to prevent splinters and ensure a clean finish.
Pro Tips:
When asked about the most effective method for trimming a door to fit without compromising its structural integrity, Steven Long shared the following insights:
“The best approach depends on the type of door—whether it’s hollow-core, solid wood, or composite—and whether you’re adjusting the height, width, or both.
General Best Practices:
- Measure twice, cut once: Always confirm the exact amount to be trimmed using a measuring tape and scribing tool for precision.
- Use the right saw: A circular saw with a fine-tooth blade (40+ teeth) is best for long, clean cuts, while a hand plane or belt sander can refine edges.
- Masking tape: Apply painter’s tape along the cut line to prevent tear-out and chipping, especially on veneered or painted doors.
- Cut incrementally: Trim small amounts at a time (⅛” per pass) to maintain control and avoid removing too much material.
- Seal the cut edges: Use wood sealer, paint, or edge banding to protect the exposed edges from moisture and prevent warping.
Trimming a Hollow-Core Door:
- Height adjustments: Hollow-core doors have a solid wood rail at the bottom and top. You can trim about ¼” to 1” before hitting the void. If more is needed, remove the cut portion, save the solid rail, and glue it back in place.
- Width adjustments: Since side rails are thin, trim only ⅛” to ¼” per side. If a larger adjustment is needed, reinforce the edge with a new wood strip and glue.
Trimming a Solid Wood Door:
- Height adjustments: Use a circular saw with a guide track for straight cuts, then sand or plane the edge for a smooth finish.
- Width adjustments: These can be trimmed more aggressively than hollow-core doors, but for best results, equal amounts should be removed from both sides to maintain balance.
- Avoid Warping: Always reseal the cut edges to prevent moisture absorption.
Trimming a Composite (MDF or Veneer) Door:
- Height adjustments: Use a fine-tooth blade and cut slowly to minimize chipping.
- Width adjustments: Avoid excessive cuts on one side; balance the trim evenly.
- Edge reinforcement: For large reductions, use a glued-on solid wood strip to maintain strength and allow for hinge installation.
By following these techniques, you can ensure a perfect fit while preserving the door’s durability and aesthetics.”
Step 4: Mark Hinge Locations and Create Mortises
After fitting the new door, use the old door as a template for the hinges. Stand the old door on its edge with the handle holes facing down. Place the new door next to it in the same direction, ensuring the top edges are flush. Use a speed square to mark the top and bottom of each hinge mortise from the old door onto the new one.
Next, use a miter saw to make shallow cuts along the marked lines on the new door. These cuts should be just deep enough for the hinges to sit flush. Then, use a hammer and chisel to remove the wood inside the marks, creating space for the hinges.
Pro Tips:
According to Steven Long, the most effective way to achieve precise hinge placement starts by aligning the new door next to the old one, ensuring their edges and tops are flush. Clamps or a straightedge help maintain proper alignment.
Next, he suggests using a marking knife or sharp pencil to trace the hinge locations from the old door onto the new one, with a combination square ensuring perfectly straight lines. For consistent and accurate mortises, Steven recommends using a router with a hinge template or jig, while a sharp chisel can fine-tune the edges for a perfect fit.
He also advises checking the mortise depth with a hinge depth gauge or the hinge itself to prevent gaps when the door is hung. To avoid splitting the wood, drilling small pilot holes before securing the hinge screws is essential. Lastly, temporarily attaching the hinges and screws allows you to check the alignment before final installation.
By blending traditional measuring techniques with power tools, Steven’s method guarantees accuracy, efficiency, and a professional finish.
Steps to Replace an Exterior Slab Door
After preparing everything, install the new slab door. This process includes attaching the hinges, hanging the door in the existing frame, and installing the lockset for security. Once you position the door, add finishing touches like sealing and painting to protect it and complete the installation.
Step 1: Install the Hinges
Once you prepare the mortises, position the hinges into the recessed areas, ensuring they sit flush with the door’s edge. Use a pencil to mark the screw hole locations, then drill small pilot holes to prevent the wood from splitting when securing the hinges. Align the hinges carefully and attach them using the included screws, tightening them firmly to ensure a secure fit.
Before installing the door, check that all six sides are properly finished. Inspect the door’s fit within the frame, ensuring it aligns correctly with the jamb. Make final adjustments to ensure the door swings smoothly and closes securely if necessary.
Step 2: Hang the New Door in Place
Start by positioning the door in the opening to check its fit. Carefully lift the door and align it with the existing hinge mortises on the door jamb. Hold the door steady while placing the hinges into the recessed areas.
Once properly positioned, insert the screws through the hinge holes and tighten them securely. Make sure you position the hinges flush with the jamb and that the door swings smoothly before proceeding.
Step 3: Prepare Lockset and Deadbolt
Using the included lockset template and the previous bore measurements as a guide, position the template on the door edge. Secure it in place with tape to prevent movement.
Next, use a 2 1/8-inch hole saw to drill through the face of the door for the lockset and deadbolt installation. Be sure to drill from one side until you see the center bit emerge, then complete the hole from the opposite side to prevent splintering.
After that, use a 1-inch spade bit to drill through the door’s edge, creating the opening for the latch and deadbolt. Work slowly to maintain accuracy and avoid damaging the wood.
Once you drill the holes, use a chisel and hammer to carve out shallow recesses on the door’s edge for the latch and deadbolt faceplates. The recesses should be deep enough for the faceplates to sit flush with the surface, ensuring a secure and clean installation.
Step 4: Install the Lockset and Deadbolt
To install the lockset and deadbolt, insert the latch mechanisms into their designated holes on the door’s edge, ensuring the curved side faces the closing direction, and secure them with screws.
Next, insert the exterior lockset through the hole, align it with the latch, then attach the interior side and tighten the screws. Repeat the process for the deadbolt, making sure the keyhole is on the correct side.
Once you install both, test the knobs and key for smooth operation. Finally, attach the strike plates to the door frame, chiseling shallow recesses if needed so they sit flush, then secure them with screws.
Step 5: Finishing Touches
Check your work by closing the door and testing both the lockset and deadbolt to ensure they latch securely. Turn the knob and key to confirm smooth operation and proper alignment. If the door sticks or doesn’t lock properly, make any necessary adjustments to the hinges, strike plates, or latch alignment.
If your door came pre-finished from the store, you don’t need to do any additional painting. However, if it only has a primer coat, you will need to apply a finish coat of paint or stain. This not only enhances the door’s appearance but also protects it from moisture, wear, and weather damage.
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Read more:
- How to Hang a Door
- How to Hang a Prehung Exterior Door
- How to Hang a Prehung Interior Door
- How to Hang an Interior Door in an Existing Frame
Main Photo Credit: Freepik
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